Optical composites between similar and between dissimilar materials

Abstract

Manufacturing techniques and composite structures that are able to meet increasing demanding requirements for large-scale crystal composites (e.g., greater than 100-200 mm in dimensions) that can be manufactured within reasonable time frames. A method of making an optical composite comprises providing first and second components to be bonded along respective surfaces, treating at least one component over at least a portion of the respective surface, and thereafter, bringing the first and second components into optical contact for bonding along the surface having the treated layer. Treating can include one or more of processing the component to provide a porous interface layer, processing the component to form a pattern of channels on the surface to be bonded, and providing an optical coating on the surface to be bonded.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS AND DOCUMENTS INCORPORATED BY REFERENCE[0001]This application claims priority from the following three provisional U.S. patent applications, the entire disclosures of which (including attached documents) are incorporated by reference for all purposes:[0002]1. U.S. Patent Application No. 60 / 703,720, filed Jul. 29, 2005, titled “Optical Composites Between Similar and Between Dissimilar Materials” and naming as inventors Huai-Chuan Lee, Helmuth E. Meissner, and Oliver R. Meissner;[0003]2. U.S. Patent Application No. 60 / 808,297, filed May 24, 2006, titled “Optical Composites Between Similar and Between Dissimilar Materials” and naming as inventors Huai-Chuan Lee, Helmuth E. Meissner, and Oliver R. Meissner; and[0004]3. U.S. Patent Application No. 60 / 833,695, filed Jul. 26, 2006, titled “Optical Composites Between Similar and Between Dissimilar Materials” and naming as inventors Huai-Chuan Lee, Helmuth E. Meissner, and Oliver R. Meissner.STATEMENT...

AI Technical Summary

Benefits of technology

This approach significantly reduces bonding time, prevents entrapment of volatile species, and achieves stress-free bonds between dissimilar materials, enabling the production of large-scale crystal composites with improved optical performance and mechanical stability.

Problems solved by technology

With the advent of requirements for high energy lasers for defense and materials processing applications, difficulties arise when components with longer and wider interfaces are to be optically contacted and heat-treated for bonding.

Subjecting such an interface prematurely to heat treatment may result in complete or partial separation of the components, or in entrapment of impurities and contaminants at the interface or other interface defects.

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